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JCB HAND HELDHYDRAULIC EQUIPMENT
717370717370
SERVICE MANUAL
9803/1250ISSUE 2
MAY 04PRINTED IN ENGLAND
SE
RV
ICE
MA
NU
AL :
JCB
HA
ND
HE
LD H
YD
RA
ULIC
EQ
UIP
ME
NT
9803/1250
ISS
UE
2
*9803/1250*
JCB Attachments, Riverside, Rugeley, Staffordshire WS15 2WA, EnglandTel: 01889 572700
INTRODUCTION Section AMAINTENANCE (HM 22, 25, 29) Section BMAINTENANCE (OTHERS) Section CSPECIFICATION Section DHYDRAULIC POWERPACKS Section E
9803/1250 Issue 2
CONTENTS
!!��WARNINGStudy this service manual before attempting to maintain thebreaker. You must understand and follow the instructions in thisservice manual. If you are unsure of anything ask your JCB dealeror employer. Do not guess, or you or others could be killed orseriously injured.
A1 INTRODUCTION
9803/1250
A1
Issue 2
ABOUT THIS MANUAL
To ensure that the JCB series of hydraulic breakerscan be operated efficiently and safely, they must beserviced and maintained regularly. This manual isdesigned to give you a good understanding of thebreaker and provide detailed maintenance information.
It is assumed that personnel carrying out maintenancehave at least a sound knowledge of workshoppractice, safety procedures and general techniquesassociated with the repair of hydraulic equipment.Details of such are, therefore, generally omitted fromthe manual, the intention being to convey only themore specialised information concerning particularaspects of the breaker or component in question.
For example, renewal of oil seals, gaskets etc. and anycomponent showing obvious signs of wear or damageis expected as a matter of course and information onthese matters, therefore, only included where aspecialised procedure or range of wear tolerances isrequired. Similarly, it is expected that components bethoroughly cleaned and lubricated, where appropriate,also that any opened hose connections will be blankedto prevent entry of dirt and excessive loss of hydraulicfluid.
For specific details regarding choice of breaker,operation and choosing steels etc., reference shouldbe made to the Operator’s Handbook which wassupplied with the breaker.
USING THIS MANUAL
Read this manual from front to back before attemptingto maintain the breaker for the first time. Particularattention must be given to all the safety aspects whichare provided. General safety warnings are given in thischapter and specific safety warnings are giventhroughout the book. Read all the safety warningsregularly so you do not forget them.
UNITS OF MEASUREMENT
The S.I. system is used throughout. For example,liquid capacities are given in litres. The Imperial unitsare given in parentheses ( ) e.g. 28 litres (6 U.K.gal).
EHTMA CATEGORIZATION
BREAKER MODEL AND SERIAL NUMBER
The following breakers are covered by this manual:
1 Standard handle breakers2 Vibro-damped handle breakers3 ‘D’ handle picks4 ‘T’ handle picks5 HM 226 HM 257 HM 298 HM 26 (Non EU)
The serial number of your breaker is stamped on thebreaker as shown. It is important to quote the serialnumber when making repairs or ordering parts.Identification of the serial number is the only means ofensuring that you receive the correct part for yourparticular breaker.
The JCB series of hydraulic breakers are categorizedby the EHTMA as Category ‘C’ or ‘D’ breakers and canbe safely used on any hydraulic powerpack displayingthe green EHTMA ‘C’ or ‘D’ decals as shown below.
c20LPM AT 138 BARETHMA CATEGORY
D30LPM AT 138 BARETHMA CATEGORY
TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "D" POWERPACKS
TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "C" POWERPACKS
Only use the following torque settings when no setting is specified in the manual.
CAUTION: All bolts used on JCB equipment are high tensile and must not under any circumstances be replacedwith bolts of a lesser tensile specification.
TABLE OF IMPORTANT TIGHTENING TORQUES
Tightening Points Tightening Torques CapscrewNm kgf m lbf ft Size
Top cover to head capscrews (Standard, 20 kg & 23 kg) 135 13.8 100 M12 Top cover to head capscrews (Standard, 26 kg) 215 21.9 158 M14
Handle bracket to head capscrews (Vibro, 22 kg & 25 kg) 135 13.8 100 M12Handle bracket to head capscrews (HM22 & HM25) 135 13.8 100 M12Handle bracket to head capscrews (Vibro, 28 kg) 215 21.9 158 M14Handle bracket to head capscrews (HM29) 215 21.9 158 M14
Handle to top cover capscrews (Standard, 20kg, 23kg & 26 kg) 67 6.8 50
Top cover to Handle bracket capscrews (Vibro, 22kg, 25kg & 28 kg) 16 1.6 11.9Top cover to Handle bracket capscrews (HM22,HM25,HM29) 16 1.6 11.9
Barrel to nose capscrews (Standard 20, 23 kg & Vibro 22, 25kg) 135 13.8 100 M12Barrel to nose capscrews (HM22 & HM25) 135 13.8 100 M12Barrel to nose capscrews (Standard 26 kg & Vibro 28 kg) 215 21.9 158 M14Barrel to nose capscrews (HM29) 215 21.9 158 M14
Head assy to barrel/nose assy (Standard 20 kg & Vibro 22 kg) 135 13.8 100 M12Head assy to barrel/nose assy (HM22) 135 13.8 100 M12Head assy to barrel/nose assy (Standard 26 kg & Vibro 28 kg) 215 21.9 158 M14Head assy to barrel/nose assy (HM29) 215 21.9 158 M14
Accumulator top to head capscrews (‘D’ & ‘T’) 80 8.1 59 M10
Barrel to head capscrews (‘D’ & ‘T’) 135 13.8 100 M12
Note:Check breaker specification to match breaker weight with the model number of your breaker.(see Section D)
A2 INTRODUCTION
9803/1250
A2
Issue 2
TORQUE SETTINGS
A3 INTRODUCTION
9803/1250
A3
Issue 1
SAFETY DECALS
Decals on the breaker warn you of particularhazards.Read, and make sure you understand thesafety message before you work with the breaker.
Keep all decals clean and readable. Replace lost ordamaged decals. The decals and their attachmentpoints on the breaker are as shown. Each decal has apart number printed on it. Use this number to order anew decal from your JCB Distributor, specifying thelanguage required.
In addition to the decals shown in the illustrationbelow, possibly three (3) other decals may be fitted.These are year/model number, tool size and modeltype. They have been omitted from the illustration forclarity.
The model shown is an HM 25 but all other models aresimilar.
55
B MAINTENANCE
9803/1250
B
Issue 1
CONTENTS
Lubricants - Health and Safety B1HygieneStorageHandlingFirst aid - OilFiresWaste disposal
Service Schedules B2DailyMonthly
Breaker dismantling - HM22, 25, 29 B3
Breaker inspection - HM22, 25, 29 B6
Breaker assembly - HM22, 25, 29 B8
Charging the accumulator B11Equipment requiredCharging pressureCharging procedure
Fault Finding B12
Specifications - HM22, 25, 29 B12
Exploded View - HM26 (Non EU) B13
Servicing - HM26 (Non EU) B14
Exploded View - HM22, 25, 29 B15
NOTE: SEE SECTION C FOR MAINTENANCE OF BREAKERSOTHER THAN HM22, 25 OR 29.
B1 MAINTENANCE
9803/1250
B1
Issue 1
LUBRICANTS - HEALTH AND SAFETY
It is most important that you read and understand thisinformation and the publications referred to. Make surethat all of your colleagues who are concerned withlubricants read it too.
Hygiene
JCB lubricants are not a health risk when usedproperly for their intended purpose.
However, excessive or prolonged skin contact canremove the natural fats from your skin, causingdryness and irritation.
Low viscosity oils are more likely to do this, so takespecial care when handling used oils which may bediluted with fuel contamination.
Whenever you are handling oil products you shouldmaintain good standards of care and personal andplant hygiene. For details of these precautions weadvise you to read the relevant publications issued byyour Local Health Authority, plus the following.
Storage
Always keep lubricants out of reach of children. Neverstore lubricants in open or unlabelled containers.
Handling
New OilThere are no special precautions needed for thehandling or use of new oil, beside the normal care andhygiene practices.
Used OilUsed oils contain harmful contaminants. Here are precautions to protect your health when handling used oil.
1 Avoid prolonged, excessive or repeated skincontact with used oil.
2 Apply a barrier cream to the skin before handlingused oil.
3 Note the following removing oil from the skin:
a Wash your hands thoroughly with soap andwater.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirtyhands.
d Never use petrol, diesel fuel or paraffin forwashing.
e Avoid skin contact with oil soaked clothing.
f Do not keep oily rags in pockets.
g Wash dirty clothing before reuse.
h Throw away oil soaked shoes.
First Aid-Oil
SwallowingIf oil is swallowed do not induce vomiting. Get medicaladvice.
EyesIn the case of eye contact, flush with water for 15minutes. If irritation persists get medical attention.
SkinIn the case of excessive skin contact, wash with soapand water.
SpillageAbsorb on sand or a locally approved brand ofabsorbent granules. Scrape up and remove to achemical disposal area.
FiresExtinguish with carbon dioxide, dry chemical or foam.Firefighters should use self -contained breathingapparatus.
Waste Disposal All waste products should be disposed of inaccordance with the relevant regulations.
The collection and disposal of used oil should be inaccordance with any local regulations. Never pourused oil into sewers, drains or on the ground.
B2 MAINTENANCE
9803/1250
B2
Issue 1
SERVICE SCHEDULES
To make sure your breaker keeps working to maximumefficiency, it is essential that it is properly and regularlymaintained in accordance with the service schedulesincluded in this manual.
Badly maintained equipment can be a danger to theoperator and the people working around him. Makesure that the regular maintenance and lubrication jobslisted in the service schedules are done to keep theequipment in a safe and efficient working condition.
Any defects found during the regular routinemaintenance checks must be rectified before theequipment is used.
Daily
Clean
1 The breaker, its steels and its hoses.
Check (Breaker disconnected)
2 All hydraulic connections.
3 For damage to the breaker, its steels and itshoses.
Monthly
Check (Breaker disconnected)
1 Torque tightness of all fasteners.
2 The hexagon bush in the nose casting for wear ordamage.
3 The cutting steel shanks for excessive wear.
Lubricate
1 Vibro-damped handle types only. Spray thetrigger and all contacting parts with suitablelubricant.
Every 600 Operating Hours or Yearly(which ever occurs first.)
1 Overhaul the breaker.
!! WARNINGMaintenance work must only be done bycompetent personnel.A-3-1-1
!! CAUTIONOnly use lubricants and hydraulic fluidsrecommended by JCB Attachments.
B3 MAINTENANCE
9803/1250
B3
Issue 1
BREAKER DISMANTLING - HM 22, 25, 29
6 Unscrew and remove check valve E ensuring thatthe breaker is positioned as shown above so asto avoid losing the check valve ball F.
5 Push the piston C and piston feeder D out of thebarrel. Remove 3 ‘O’ rings from the barrel.
CCDD
FFEE
4 Prepare for oil spillage and remove the two upperbarrel fixing capscrews. Remove the barrel A.
AA
3 Before commencing dismantling, cleanexternally. Remove the hoses. Remove the twolower barrel fixing capscrews. Separate thebarrel A from the nose B.
BB
AA
1 Using a press, remove roll pins Q from thenose.This releases latch R, latch plunger S andthe plunger spring.
SS
OO
RR
2 Unless signs of damage or wear are evident it isnot necessary to remove the tool bush. Removalwill be dealt with in the following ‘BreakerInspection’.
B4 MAINTENANCE
9803/1250
B4
Issue 1
BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)
7 Remove the seals from the lower section of thebarrel casting. A slide hammer will be necessaryto remove the seal housing.
8 Remove the housing cap G and the spool H fromthe head J.
12 Remove vibration dampening springs.
11 Unscrew the handle pivot pin Z nearest thetrigger pin. Withdraw handles assemblies fromthe handles control bracket.
ZZ
ZZGG
JJ
HH
10 Remove screws (4 off each cover) from covers N(2 off), this will expose the handle mechanism.
NN
9 Remove the plug K, seal washer L, spring andtrigger spool M from the head J. Examine sealson the head J and housing cap G.
JJ
MMLL
KK GG
B5 MAINTENANCE
9803/1250
B5
Issue 1
BREAKER DISMANTLING - HM 22, 25, 29 (cont’d)
13 Remove the cover screw T to expose thecharging screw.
14 Loosen the charging screw U slowlyapproximately 3 or 4 turns, listening for all thegas to escape. Refit the cover screw T.
15 When you are sure that all the gas in theaccumulator has been evacuated, remove thesafety screw V from the head.
16 Remove the four top cover retaining screws Pand remove the cover.
Note: There are two long and two shorter retainingscrews
18 Remove the diaphragm X from the head.
XX
17 Remove the trigger pin W and the ‘O’ ring seal Yfrom the head.
WWYY
PP
PP
VV
UU
TT
TT
B6 MAINTENANCE
9803/1250
B6
Issue 1
BREAKER INSPECTION - HM 22, 25, 29
1 Examine the piston C, piston feeder D and barrelA for signs of damage. Small scratches can becarefully removed with fine emery cloth.
2 Deep grooves or signs of pick-up (especially onthe lower sealing portion of the piston) will requirereplacement of the component. Examine seal onfeeder D, replace if necessary.
3 Examine the check valve ball F and ball seats forsigns of damage or excessive wear. Obtain newcomponents if necessary.
4 Examine the seals for signs of wear. Payparticular attention to their lips. Obtain new sealsif necessary or if the piston is changed.
5 Examine the housing cap G and spool H forsigns of damage. Obtain new components ifnecessary.
6 Examine the plug K, seal washer L, spring andtrigger spool M for signs of damage or wear.Obtain new components if necessary.
AACC
DD
AACC
DD
FF
HH
GG
MMLL
KK
JJ
JJ
B7 MAINTENANCE
9803/1250
B7
Issue 1
BREAKER INSPECTION - HM 22, 25, 29 (cont’d)
7 Examine the roll pins Q, latch R, latch plunger Sand plunger spring for signs of damage or wear.Obtain new components if necessary.
8 Should it be necessary to remove thecomponents of the tool bushing, firstly push inthe spring ring aa with a sharp instrument via thehole shown at cc.
9 Grip the spring ring aa with a suitable pair ofpincers ee and remove. The sliding bush andother components can now be removed from thenose (see item 10).
10 Check the spring ring aa, guide rings ff (2 off),carrier ii, spring jj and tool bush nn for damageand wear. Replace as necessary.See Note:below
11 Examine the diaphragm X for signs of damage.Pay particular attention for signs of crackingaround the diaphragm insert. Replace asnecessary.
SS
RR
aa
ee
aa
iijj
nn
ff
XX
cc
aa
Note: A hydraulic press will be required to remove toremove the steel tool bush nn. See item 10.
B8 MAINTENANCE
9803/1250
B8
Issue 1
BREAKER ASSEMBLY - HM 22, 25, 29
Note: During assembly, apply Multi Gasket Loctite518 (JCB Part No. 4102/1212) to all joint faces. Usenew seals and ‘O’ rings throughout.
1 Place diaphragm X into the head, ensuring thatthe diaphragm insert is uppermost (as shownabove). Fit new ‘O’ ring seal Y.
2 Fit the trigger spool M, spring, seal washer L andplug K into the head J. Fit seal on head unit J.
3 Fit the trigger pin O into the handle bracket. Fitthe handle bracket to the head. Treat the threadsof the safety screw V with Loctite 270 and fit tothe head.
4 Fit the handle assembly springs. Coat thecontacting surface of the handle furthest fromthe trigger pin (see item 5) and fit to the handlebracket.
5 The illustration above shows the trigger handleafter coating with a suitable lubricant beforefitting.
! CAUTIONBefore commencing assembly, all componentsmust be scrupulously cleaned.A-3-1-4
XX
YY
KK
LLMM
JJ
OO
VV
B9 MAINTENANCE
9803/1250
B9
Issue 1
BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)
6 Treat the thread of the pivot pin Z with Loctite270 and fit the pin where indicated.
7 Check that all parts of the trigger and other partsin contact are well coated with lubricant. (seeitem 5)
8 Fit the housing spool H and the housing seal Ginto the head J. Fit a new ‘O’ ring to the housingseal G.
9 Assemble the seals into the lower section of thebarrel casting A. Ensure seal ss has the openface uppermost,seal zz is fitted in the samedirection.
10 Treat the threads E of the check valve withLoctite 542. Ensure that the ball F is clean andundamaged. Obtain a new seal. Assemble thecheck valve.
11 Fit the check valve into the barrel A. Alwaysensure that ball F has been fitted.
ZZ
ZZ
GG
JJ
HH
ss
zz
A
EEFF
FFEEEE
AA
tt
MAINTENANCE
9803/1250
B10
Issue 1
BREAKER ASSEMBLY - HM 22, 25, 29 (cont’d)
12 Bolt the barrel A to the nose B. Torque tightenthe capscrews progressively using a Gedorenarrow head torque wrench (part no. 7200-01).See Torque Figures on Page A2
13 Fit 3 new seals into barrel A. Insert the piston Cand piston feeder D into the barrel A.
14 Fasten the barrel A/nose B assembly onto thehead assembly using the capscrews and a Gedoretorque wrench (part no. 7200-01). See TorqueFigures on Page A2.
15 Replace covers N (2 off).
AA
BB
DDCC
AA
AA
BB
NN
B10
B11 MAINTENANCE
9803/1250
B11
Issue 1
CHARGING THE ACCUMULATOR - HM 22, 25, 29
X3
743310
! WARNINGUse only nitrogen gas to charge the accumulators. Theuse of any other gas can cause the accumulators toexplode. Remember that although nitrogen is notpoisonous, you can be killed by suffocation if it displacesair in your workplace. Do not allow excessive quantitiesof nitrogen to be discharged into the atmosphere.
This procedure must not be carried out with the breaker(or pick) connected to a source of hydraulic supply.
During charging, the breaker must be securely mountedin the upright position. This prevents the breaker fallingover whilst charging, thereby preventing uncontrolledescape of gas.
EQUIPMENT REQUIRED.
a Nitrogen bottleMinimum residual pressure 70 bar (1000lbf/in2 )
b Regulator (with contents and outlet gauge)Outlet pressure should be controllable up to 55 bar(800 lbf/in2 )
c Charging adaptor (JCB part no. 929/05800)together with 3/8 in. BSP Dowty washer.
d Connecting hoseSuitable hose of minimum operating pressure 207 bar(3000 lbf/in2), together with female coupling (JCB partno.929/06303).
CHARGING PRESSURE
The charging pressure should not exceed 50 bar (800lbf/in2). Refer to Specification section for specificaccumulator pressures.
CHARGING PROCEDURE
1 Remove the slotted cover screw 1 from the breaker.
2 Using a 4 mm. Allen key 2, slowly loosen the chargingscrew approximately 3 turns. Do not remove the screw.
3 Fit the 3/8 in. Dowty washer 5 to the charging adaptor 3and screw into the breaker. Do not overtighten, handtight is adequate.
4 Ensure that the nitrogen bottle outlet pressure is at zeroand then connect the charging hose 4 to the chargingadaptor 3.
5 Gradually increase the nitrogen bottle outlet pressureuntil the required level is reached (see Specificationsection).
6 Push in knob 6 on the charging adaptor 3 to engage thecharging screw and tighten. Do not overtighten.
7 Shut the regulator valve on the nitrogen bottle and usingthe venting screw 7, release the trapped gas in thehose.
8 Disconnect the charging hose 4 and unscrew thecharging adaptor 3 from the body of the breaker.
9 Finally, tighten the charging screw using a 4mm. Allenkey 2 and refit the cover screw 1 after applying Loctite270 to the threads.
44
3322
6677 11
55
B12 MAINTENANCE
9803/1250
B12
Issue 1
OPERATOR FAULT FINDING
Specifications
*The remedy in certain cases should be carried out by your JCB dealer
Symptom Possible Fault Remedy
Breaker fails to operate. No flow from supply. *Check output with flow and pressure tester.
Hoses incorrectly fitted. Check that pressure feed is connected to top port on the breaker.
Insufficient movement of *The trigger spool should move approx. trigger spool. 5mm (0.2in.). Check lever mechanism.
Main spool jammed or *Remove and check.damaged. Clean all associated parts.
Striker piston seized. *Remove and check for 'pick-up' on piston feeder or barrel. Replace any damaged parts.
Breaker lacks breaking power. Insufficient available *Check Main Relief Valve -pressure. minimum setting 76 bar (1100 lbf/in2) for the 22 kg
Breaker and 110 bar (1595 lbf/in2) for the 25 and 29 kg Breaker.
Low accumulator gas pressure *Re-charge the accumulator(Normally associated withviolent shaking of hoses).
Hexagon bush in nose Apply JCB Retainer( High Strength ) and press back.casting loose.
Breaker runs slow Insufficient flow. *Check that the flow rate is between18 - 22 l/min. (3.96 - 4.84 gal/min.).
Note: For HM29 (30 litre.) flow rate 28 - 32l/min (6.16 - 7.04 gal/min).
Cold oil. Warm up the oil supply. Optimum temperature 20 - 70C (68 - 158F).
High return line back pressure. *Check return line back-pressure.Pressure should not exceed12 bar (174 lbf/in2).
Incorrect oil. Use only JCB Hydraulic Oil HP32(part no. 4002/1000).
Breaker runs hot. Inadequate cooling of Check oil supply has adequate cooling.hydraulic oil. Temperature should not exceed
80C (176F).
Noise Level Standard:Noise Level EC Directive 84/537/EEC (Lwa)Vibration Standard:Vibration Weighted RMS Acceleration ISO 8662 Part 5 (m/s2)
Min. Acc.EHTMA Pressure Relief Valve Gas
Model Length Weight Steel Size mm (in) Noise Level Vibration Category Flow Rate Range Settings Pressure929/92400 760 mm 25 kg 32 x 160 (11/4 x 61/4) 109 Lwa 4.0 m/s 2 C 18-22 L/Min 90-110 bar 110 bar 43 bar
929/92500 720 mm 22 kg 22 x 82.5 (7/8 x 31/4) 106 Lwa 3.4 m/s 2 C 18-22 L/Min 69-86 bar 76 bar 38 bar
929/92600 680 mm 22 kg 25 x 108 (1 x 41/4) 106 Lwa 3.4 m/s 2 C 18-22 L/Min 69-86 bar 76 bar 38 bar
929/92700 730 mm 29 kg 32 x 160 (11/4 x 61/4) 108 Lwa 5.0 m/s 2 C 18-22 L/Min 90-110 bar 110 bar 50 bar
929/92900 730 mm 29 kg 32 x 160 (11/4 x 61/4) 110 Lwa 5.9 m/s 2 D 28-32 L/Min 90-110 bar 110 bar 50 bar
B13 MAINTENANCE
9803/1250
B13
Issue 1
BREAKER HM26 (NON EU)
B14 MAINTENANCE
9803/1250
B14
Issue 1
BREAKER HM26 (NON EU)
HM26 (NON EU) - Servicing
It should be noted that, when servicing this breaker(shown on page B12), detail for the handle onlyreference should be made to Section C - Standardhandle breakers(from 9803/1250 Issue 1).
The remainder of the breaker , head, barrel and nosesections, are covered in Section B - respectivesections.
B15 MAINTENANCE
9803/1250
B15
Issue 1
BREAKER - HM22, 25, 29
C MAINTENANCE
9803/1250
C
Issue 1
CONTENTS
Breaker dismantling - Standard and Vibro-damped C1
Breaker inspection - Standard and Vibro-damped C5
Breaker assembly - Standard and Vibro-damped C7
Breaker dismantling - ‘D’ and ‘T’ picks C8
Breaker inspection - ‘D’ and ‘T’ picks C14
Breaker - ‘D’ and ‘T’ picks C16
Charging the accumulator C19Equipment requiredCharging pressureCharging procedure
Fault Finding C20
C1 MAINTENANCE
9803/1250
C1
Issue 1
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED
!! WARNINGAccumulator
The breaker incorporates a pressure accumulator.This accumulator is pressurised even when there isno hydraulic pressure to the breaker. Attempting todismantle the accumulator without first releasingthe pressure can cause injury or death. Thisprocedure must be carried out by a qualifiedperson.
Note: Unless otherwise indicated, the followinginstructions apply to both the standard handle andvibro-handle type breakers.
2 Remove the hoses. Remove the two lower barrelfixing capscrews. Separate the barrel A from thenose B.
4 Prepare for oil spillage and then remove the twoupper barrel fixing capscrews. remove the barrelA.
!! WARNINGThe breaker must be disconnected from its sourceof hydraulic power before any maintenance iscarried out.
1 Before commencing dismantling, thoroughlyclean all external parts.
3 The lower portion of the piston C and the sealhousing and seal will be exposed.
5 Push the piston C and piston feeder D out of thebarrel.
C2 MAINTENANCE
9803/1250
C2
Issue 1
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)
6 Unscrew and remove check valve E ensuring thatthe breaker is positioned as shown above so as toavoid losing the check valve ball F.
8 Remove the housing cap G and the spool H fromthe head J.
10 For standard handle breakers only, Using apress, remove roll pins N from the top cover andremove the trigger. Withdraw the trigger pin O.
7 Remove the seals from the lower section of thebarrel casting. A slide hammer will be necessaryto remove the seal housing.
9 Remove the plug K, seal washer L, spring andtrigger spool M from the head.
11 For standard handle breakers only, remove thecapscrew from inside each handle and removethe handles from the top cover.
C3 MAINTENANCE
9803/1250
C3
Issue 1
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)
12 For vibro-damped handle breakers only, removethe four top cover retaining screws P and removethe cover.
14 For vibro-damped handle breakers only,withdraw the remaining handle assemblycomplete with handle pivot. Remove the springs.
!! WARNINGAccumulator
The breaker incorporates a pressure accumulator.This accumulator is pressurised even when there isno hydraulic pressure to the breaker. Attempting todismantle the accumulator without first releasingthe pressure can cause injury or death. Gaspressure must be released before carrying outfurther dismantling.
Note: Once gas has been released, a special chargingtool (part no. 929/05800) is required to re-charge theaccumulator. Re-charging the accumulator must onlybe undertaken by a suitably qualified person.
13 For vibro-damped handle breakers only,unscrew the handle pivot pin Z nearest the triggerpin. Withdraw the handle assembly from thecontrol handles bracket.
15 For vibro-damped handle breakers only, usinga press, remove roll pins Q from the nose. Thisreleases latch R, latch plunger S and the plungerspring.
16 Remove the cover screw T to expose thecharging screw.
C4 MAINTENANCE
9803/1250
C4
Issue 1
BREAKER DISMANTLING - STANDARD AND VIBRO-DAMPED (cont’d)
17 Loosen the charging screw U slowlyapproximately 3 or 4 turns, listening for all the gasto escape. Refit the cover screw T.
19 For standard handle breakers only, remove thefour capscrews and remove the cover from thehead.
21 For vibro-damped handle breakers only,withdraw the trigger pin O. Remove the fourcapscrews and remove the handle bracket fromthe head.
18 For standard handle breakers only, when youare sure that all the gas in the accumulator hasbeen evacuated, remove the safety screw V fromthe head.
20 For vibro-damped handle breakers only,whenyou are sure that all the gas in the accumulatorhas been evacuated, remove the safety screw Vfrom the head.
22 Remove the diaphragm X and ‘O’ ring seal Y fromthe head.
C5 MAINTENANCE
9803/1250
C5
Issue 1
BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED
1 Examine the piston C, piston feeder D and barrelA for signs of damage. Small scratches can becarefully removed with fine emery cloth. Deepgrooves or signs of pick-up (especially on thelower sealing portion of the piston) will require thereplacement of the component.
3 Examine the seals for signs of wear. Pay particularattention to their lips. Obtain new seals ifnecessary.
5 For standard handle breakers only, examine therubber bushes inside the handles for signs ofdamage. Fit new bushes if necessary. Thesebushes are a press fit inside the handles and canbe removed by slitting their cores from the insideand driving out.
2 Examine the check valve ball F and ball seats forsigns of damage or excessive wear. Obtain newcomponents if necessary.
4 Examine the housing cap G and spool H for signsof damage. Obtain new components if necessary.
6 Examine the plug K, seal washer L, spring andtrigger spool M for signs of damage or wear.Obtain new components if necessary.
C6 MAINTENANCE
9803/1250
C6
Issue 1
BREAKER INSPECTION - STANDARD AND VIBRO-DAMPED (cont’d)
7 Examine the roll pins Q, latch R, latch plunger Sand plunger spring for signs of damage or wear.Obtain new components if necessary.
9 Examine the bush inside the nose for signs ofdamage or wear. If it is necessary to remove thebush it can be pressed out from the top of thehousing using a suitable hydraulic press ofapproximately 20 tonnes.
8 Examine the diaphragm X for signs of damage.Pay particular attention for signs of crackingaround the diaphragm insert. Obtain a newdiaphragm if necessary.
C7 MAINTENANCE
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Issue 1
BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED
!! CAUTIONBefore commencing assembly, all componentsmust be scrupulously cleaned.A-3-1-4
Note: During assembly, apply Multi Gasket Loctite 574(JCB Part No. 4102/1201) to all joint faces.
2 Fit the trigger spool M, spring, seal washer L andplug K into the head.
4 For standard handle breakers only, assemblethe top cover onto the head and fit the fourcapscrews. Torque tighten the capscrewsprogressively (see Introduction section), ensuringtheat the trigger pin remains free to move.
1 Place diaphragm X into the head, ensuring thatthe diaphragm insert is uppermost (as shownabove). Fit new ‘O’ ring seal Y.
3 For standard handle breakers only, insert thetrigger pin O. Assemble the trigger onto the topcover and fit roll pins N using a press.
5 For vibro-damper handle breakers only, fit thetrigger pin O. Assemble the handle bracket ontothe head and fit the four capscrews. Torquetighten the capscrews progressively (seeIntroduction section), ensuring that the triggerpin remains free to move.
C8 MAINTENANCE
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Issue 1
BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d)
6 Treat thread of safety screw V with Loctite 242and fit the safety screw into the head.
8 For vibro-damped handle breakers only, fit theremaining handle assembly. Treat the thread ofpivot pin Z with Loctite 242 and fit the pin. Spraythe handles, trigger and all contacting parts with asuitable lubricant.
10 For standard handle breaker only, fit the handlesto the top cover with capscrews. Torque tightenthe capscrews (see Introduction section).
7 For vibro-damped handle breakers only, fit thehandle assembly springs. Fit the handle assemblyfurthest from the trigger pin complete with pivotpin into the handle bracket (see Step 14 ofDismantling).
9 For vibro-damped handle breakers only,assemble the top cover onto the handle bracket.Treat the threads of the top cover capscrews withLoctite 242 and torque tighten (see Introductionsection).
11 Fit the housing spool H and housing seal G intothe head. Fit a new ‘O’ ring to the housing seal.
C9 MAINTENANCE
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Issue 1
BREAKER ASSEMBLY - STANDARD AND VIBRO-DAMPED (cont’d)
12 Assemble the seals into the lower section of thebarrel casting. Ensure that the open faces of theseals are fitted as shown on inset.
14 Bolt the barrel to the nose with capscrews. Torquetighten the capscrews progressively (seeIntroduction section) using a Gedore narrowhead torque wrench (part no. 7200-01). Do notuse a standard torque wrench fitted with auniversal joint as this distorts the torque setting.
16 Assemble the head assembly onto the barrel/noseassembly and fit the capscrews. Torque tightenthe capscrews progressively (see Introductionsection) using a Gedore narrow head torquewrench (part no. 7200-01- see Step 14 above). Fitthe hoses, ensuring that the hose with the femalecoupling is fitted to the top port of the headassembly.
13 Treat the thread of check valve E with Loctite 542.Fit the check valve and its ball F into the barrel byoffering the check valve to the barrel fromunderneath to avoid losing the ball.
15 Insert the piston C and piston feeder D into thebarrel.
17 Assemble the plunger spring, plunger S, and latchR into position in the nose. Using a press, insertroll pins Q to secure the mechanism.
C10 MAINTENANCE
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Issue 1
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS
!! WARNINGAccumulator
The breaker incorporates a pressure accumulator.This accumulator is pressurised even when there isno hydraulic pressure to the breaker. Attempting todismantle the accumulator without first releasingthe pressure can cause injury or death. Thisprocedure must be carried out by a qualifiedperson.
!! CAUTIONBefore commencing assembly, all componentsmust be scrupulously cleaned.A-3-1-4
Note: Unless otherwise indicated, the followinginstructions apply to both the ‘D’ type and ‘T’ typebreakers.
2 Cut the cable tie securing the hose gaiter 1 andremove the gaiter. Remove the hoses 2 from theadaptors 3. Remove the adaptors and seals 4from the accumulator assembly.
4 If necessary, drift out the pivot pin 7 and removethe trigger 8 from the handle.
!! WARNINGThe pick must be disconnected from its source ofhydraulic power and the oil drainer before anymaintenance is carried out.
!! WARNINGUnder no circumstances should an attempt bemade to remove the handle when the pick isconnected to a source of hydraulic power.
1 Disconnect hoses and collect any residual oil intoa suitable container.
3 Remove the four capscrews 5 together withwashers 6 and remove the handle assembly.
5 Remove the push pin 9 (‘D’ Type only). Removethe spring 10, trigger pin 11 and ‘O’ ring 12 fromthe accumulator assembly. Discard the ‘O’ ring.
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BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)
6 ‘D’ Type only. Remove the retainer 13 with thebump stop 14. Remove and discard ‘O’ ring 15. ‘T’ Type only. Remove nose latch 16 with theshim assembly 17. Remove and discard ‘O’ ring15.
8 Remove the accumulator/barrel/nose assemblyfrom the upper end of the nose casting 23.
10 Remove slide bearing 27 and bump stop 26 fromboth sides then remove capscrews 28 to separatethe accumulator assembly from the barrel/noseassembly.
7 ‘T’ Type only. If necessary, remove roll pins 18and 19 suing a press. Remove the latch 20,plunger 21 and spring 22.
9 Apply light pressure to the top of slide rail 24 tocompress spring 25 then swing the bottom of theslide rail clear of bump stop 26. Remove the sliderail and the spring. Repeat for the other side.
11 Turn the accumulator assembly over. Withdrawhousing cap 29 then remove and discard ‘O’ ring30. Remove ‘O’ ring 31 from the recess in theaccumulator assembly and discard the ‘O’ ring.Withdraw spool 32 from the spool housing.
C12 MAINTENANCE
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Issue 1
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)
!! WARNINGAccumulator
The breaker incorporates a pressure accumulator.This accumulator is pressurised even when there isno hydraulic pressure to the breaker. Attempting todismantle the accumulator without first releasingthe pressure can cause injury or death. Gaspressure must be released before carrying outfurther dismantling.
Note: Once gas has been released, a special chargingtool (part no. 929/05800) is required to re-charge theaccumulator. Re-charging the accumulator must onlybe undertaken by a suitable qualified person.
13 Releasing Gas Pressure from the accumulator.Remove the cover screw 37 to gain access to thecharging screw 38. Insert a 4 mm allen key andslowly loosen the charging screw approximately 3or 4 turns listening for all the gas to escape.Tighten the charging screw approximately 3 or 4turns. Refit the cover screw.
15 Hold the barrel/nose assembly above theworkbench with the check valve housing pointingdownwards. Remove the check valve 43 with thecheck valve ball 44.
12 Remove plug 33, seal 34, spring 35 and triggerspool 36.
14 Dismantling the Accumulator Assembly (seeWARNING). Remove the four capscrews 39 andseparate the accumulator top 40 from theaccumulator head 41. Remove the diaphragm 42from the head.
16 Using a suitable drift, push out the piston 45 andpiston feeder 46 from the barrel 49. Separate thepiston from the feeder. Remove and discard ‘O’ring 47.
C13 MAINTENANCE
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Issue 1
BREAKER DISMANTLING - ‘D’ and ‘T’ PICKS (cont’d)
17 Remove the two grub screws 48 from the lowerend of the barrel 49 (one each side).
19 Remove seal 51 and seal housing 52 from thelower end of the barrel 49. Using a slide hammer,remove seal 53 from seal housing 52. Discard theseals.
18 Clamp the barrel/nose assembly in a vice andunscrew the now 50 from the barrel 49, using a‘C’ spanner.
C14 MAINTENANCE
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Issue 1
BREAKER INSPECTION - ‘D’ and ‘T’ PICKS
1 ‘T’ Type only. Examine the roll pins 18 and 19,latch 20, plunger 21 and plunger spring 22 forsigns of damage or wear. Obtain new componentsif necessary.
3 Examine the plug 33, seal 34 and trigger spool 36for signs of damage or wear. Obtain newocmponents if necessary.
5 Examine the check valve ball 44 and ball seat incheck valve 43 for signs of damage or excessivewear. Obtain new components if necessary.
2 Examine the housing cap 29 and spool 32 forsigns of damage. Obtain new components ifnecessary.
4 Examine the diaphragm 42 for signs of damage.Pay particular attention for signs of crackingaround the diaphragm insert. Obtain a newdiaphragm if necessary.
6 Examine the piston 45, piston feeder 46 andbarrel 49. Small scratches can be carefullyremoved with fine emery cloth. Deep grooves orsigns of pick-up (especially on the lower sealingportion of the piston) will require the replacementof the component.
C15 MAINTENANCE
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Issue 1
BREAKER INSPECTION - ‘D’ and ‘T’ PICKS (cont’d)
7 Examine slide rails 24 and springs 25 for signs ofexcessive wear, damage or deformation. Replaceif necessary.
8 Examine slide bearings 26 and bump stops 27 forsigns of damage or excessive wear. Replace ifnecessary.
C16 MAINTENANCE
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Issue 1
BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS
!! CAUTIONBefore commencing assembly, all componentsmust be scrupulously cleaned.A-3-1-4
Note: Unless otherwise indicated, the followinginstructions apply to both the ‘D’ type and ‘T’ typebreakers.
Note: During assembly, apply Multi Gasket Loctite 574(JCB Part No. 4102/1201) to all joint faces. Lightlylubricate all hydraulic components with hydraulic fluidprior to assembly.
2 Clamp the barrel 49 in a vice. Apply Loctite 242 tonose 50 and screw into the barrel using a ‘C’spanner.
4 Insert piston 45 into the upper end of barrel 49. Fitnew ‘O’ ring 47 to piston feeder 46 and slide thepiston feeder into the piston.
1 Insert new seal 51 into the lower end of barrel 49.Assemble new seal 53 to seal carrier 52 andinsert into barrel 49. Ensure the seals are fitted asshown.
3 Apply Loctite 242 to grub screws 48 and fit intothe lower end of barrel 49 (one each side).
5 Treat the thread of check valve 43 with Loctite542. Hold the barrel/nose assembly above theworkbench with the check valve housing pointingdownwards and fit the check valve with the checkvalve ball 44.
C17 MAINTENANCE
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Issue 1
BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d)
6 Fit the diaphragm 42 into the accumulator head41, ensuring the diaphragm insert is uppermost.Assembly the accumulator top 40 onto the headand fit the four capscrews 39. Torque tighten thecapscrews to 80 Nm (8.1 kgf m, 59 lft ft).
8 Slide spool 32 into spool housing. Fit new ‘O’ ring30 to housing cap 29 and insert into accumulatorassembly, followed by new ‘O’ ring 31.
10 Fit spring 25 and slide rail 24 as shown. Apply lightpressure to the top of the slide rail to compressthe spring then swing the bottom of the slide railover the bump stop 26. Repeat for the other side.
7 Turn the accumulator assembly over. Inserttrigger spool 36 into accumulator assembly. Fitspring 35, seal 34 and plug 33.
9 Assemble the accumulator assembly onto thebarrel/nose assembly and fit the capscrews 28.Torque tighten the capscrews to 135 Nm (14 kgfm, 100 lbf ft). Fit bump stops 26 to the heads ofthe capscrews and assemble slide bearings 27(both sides). Charge the accumulator, refer topage C19.
11 Fit the accumulator/barrel/nose assembly into theupper end of the casting 23.
C18 MAINTENANCE C18
Issue 1
13 Fit new ‘O’ ring seal 15 onto the nose 52, takingcare not to damage it on the exposed thread. ‘T’type only. Fit the shim assembly 17 and the noselatch 16. ‘D’ Type only. Fit the bump stop 14 andthe retainer 13.
15 If dismantled, fit trigger 8 to the handle and drivein pivot pin 7 to secure.
17 Assemble seals 4 and adaptors 3 to theaccumulator assembly. Fit hoses 2, ensuring thatthe hose with the female coupling is fitted to thetop port of the accumulator head. Fit the hosegaiter 1 and secure with a cable tie.
BREAKER ASSEMBLY - ‘D’ and ‘T’ PICKS (cont’d)
12 ‘T’ Type only. If dismantled, fit the spring 22,plunger 21 and latch 20 into the nose latch. Usinga press, insert roll pins 18 and 19 to secure themechanism.
14 Lubricate a new ‘O’ ring 12 and feed it into thehole in the top of the accumulator assembly; onceinside, the ‘O’ ring will expand to fill the groove. Fitthe trigger pin 11 and spring 10. ‘D’ type only. Fitpush pin 9.
16 Assemble the handle assembly onto the outercasing and fit washers 6 and capscrews 5. Notethat two of the capscrews are longer than theothers.
C19 MAINTENANCE
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Issue 1
CHARGING THE ACCUMULATOR
!! WARNINGUse only nitrogen gas to charge the accumulators.The use of any other gas can cause theaccumulators to explode. Remember that althoughNitrogen is not poisonous, you can be killed bysuffocation if it displaces air in your workplace. Donot allow excessive quantities of nitrogen to bedischarged into the atmosphere.
This procedure must not be carried out with thebreaker (or pick) connected to a source ofhydraulic supply.
During charging, the breaker must be securelymounted in the upright position. This prevents thebreaker falling over whilst charging, therebypreventing uncontrolled escape of gas.
EQUIPMENT REQUIRED
a Nitrogen bottleMinimum residual pressure 70 bar (100 lbf/in2).
b Regulator (with contents and outlet gauge)Outlet pressure would be controllable up to 55 bar(800 lbf/in2)
c Charging adaptor (JCB part No. 929/05800)together with 3/8 in. BSP Dowty washer.
d Connecting hoseSuitable hose of minimum operating pressure 207bar (3000 lbf/in2), together with female coupling(JCB part No. 929/06303)
CHARGING PRESSURE
The charging pressure should not exceed 50 bar (725lbf/in2). Refer to Specification section for specificaccumulator pressures.
CHARGING PROCEDURE
Note: For ‘D’ and ‘T’ picks, access must first begained to the accumulator assembly by carrying outSteps 1 to 8 (excluding step 7) of BreakerDismantling.
1 Remove the slotted cover screw 1 from thebreaker.
2 Using a 4 mm Allen key 2, slowly loosen thecharging screw approximately 3 turns. Do notremove the screw.
3 Fit the 3/8 in. Dowty washer to the chargingadaptor C and screw into the breaker. Do notovertighten, hand tight is adequate.
4 Ensure that the nitrogen bottle outlet pressure isat zero and then connect the charging hose D tothe charging adaptor C.
5 Gradually increase the nitrogen bottle outletpressure until the required level is reached (seeSpecification section).
6 Push in knob 6 on the charging adaptor C toengage the charging screw and tighten. Do notovertighten.
7 Shut the regulator valve on the nitrogen bottle andusing the venting screw 7A, release the trappedgas in the hose.
8 Disconnect the charging hose D and unscrew thecharging adaptor C from the body of the breaker.
9 Finally, tighten the charging screw using a 4 mmAllen key 2 and refit the cover screw 1 afterapplying Loctite 242 to the threads.
Note: For ‘D’ and ‘T’ picks, refit the accumulatorassembly by carrying out Steps 11 to 17 of BreakerAssembly. Seals need not be replaced providing theyare serviceable.
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Issue 1
FAULT FINDING
*The remedy in certain should be carried out by your JCB Dealer.
Symptom Possible Fault Remedy
Breaker fails to operate. No flow from supply. *Check output with flow and pressure tester.
Hoses incorrectly fitted. Check that pressure feed is connected to top port on the breaker.
Insufficient movement of *The trigger spool should movetrigger spool. approx. 5 mm (0.2 in). Check lever
mechanism.
Main spool jammed or *Remove and check.damaged. Clean all associated parts.
Striker piston seized. *Remove and check for ‘pick-up’ on piston feeder or barrel.Replace any damaged parts.
Breaker lacks breaking power. Insufficient available pressure. *Check Main Relief Valve - for settings refer to Specificationsection.
Low accumulator gas pressure *Re-charge the accumulator as (Normally associated with detailed in this section.violent shaking of hoses).
Hexagon bush in nose casting Apply JCB Retainer ( High Strength ) loose. and press back.
Breaker runs slow. Insufficient flow. *Check the flow rate - for settings refer to Specification section.
Cold oil Warm up the oil supply. Optimum temperature 20 - 70ºC (68 - 158 ºF).
High return line back pressure. *Check return line back-pressure. Pressure should not exceed 12 bar (174 lbf/in2).
Incorrect oil. Use only JCB Special Hydraulic Oil (part no. 4002/0224).
Breaker runs hot. Inadequate cooling of hydraulic Check oil supply has adequate oil. cooling. Temperature should not
exceed 80 ºC (176 ºF).
D SPECIFICATION
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Issue 1
CONTENTS
JCB hydraulic breakersStandard Breakers D1Vibro-damped breakers D1/D2‘D’ and ‘T’ breakers D2
Noise and vibration data D3
D1 SPECIFICATION
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Issue 1
JCB HYDRAULIC BREAKERS
STANDARD BREAKERS
Breaker weightModel Nos. 929/05400 & 05600 20 kg 44 lbModel Nos. 929/07200 & 08200 26 kg 57 lb
Breaker lengthModel Nos. 929/05400 & 05600 910 mm 36 in.Model Nos. 929/07200 & 08200 1050 mm 41 in.
Accumulator gas pressure (Nitrogen)Model Nos. 929/05400 & 05600 38 bar 551 lb/in2
Model Nos. 929/07200 & 08200 50 bar 725 lb/in2
Hydraulic supply flow rateModel Nos. 929/05400, 05600 18 - 22 l/min 3.96 - 4.84 gal/minModel No. 929/07200 18 - 22 l/min 3.96 - 4.84 gal/minModel No. 929/08200 28 - 32 l/min 6.20 - 7.00 gal/min
Hydraulic supply pressure rangeModel Nos. 929/05400 & 05600 69 - 86 bar 1000 - 1247 lb/in2
Model Nos. 929/07200 & 08200 90 - 110 bar 1300 - 1600 lb/in2
Hydraulic supply relief valve settingModel Nos. 929/05400 & 05600 76 bar minModel Nos. 929/07200 & 08200 1100 lb/in2 minAll models 138 bar max. 2000 lb/in2 max.
Hydraulic return line pressure 12 bar max. 174 lb/in2 max.
Breaker blow frequency 1500 blows/min -
Breaker shank sizeModel No. 929/05400 22 mm 7/8 in.Model No. 929/05600 25 mm 1 in.Model No. 929/07200 & 08200 32 mm 1 1/4 in.
Hydraulic supply oil type JCB Special Hydraulic Oil (part no. 4002/0224)
EHTMA Category ‘C’ or ‘D’
VIBRO-DAMPED BREAKERS
Breaker weightModel Nos. 929/05300 & 05500 22 kg 44 lbModel Nos. 929/07400 & 08300 28 kg 62 lb
Breaker lengthModel Nos. 929/05300 & 05500 930 mm 36 in.Model Nos. 929/07400 & 08300 1090 mm 43 in.
Accumulator gas pressure (Nitrogen) 50 bar 725 lb/in2
Hydraulic supply flow rateModel Nos. 929/05300 & 05500 18 - 22 l/min 3.96 - 4.84 gal/minModel No. 929/07400 18 - 22 l/min 3.96 - 4.84 gal/minModel No. 929/08300 28 - 32 l/min 6.20 - 7.00 gal/min
D2 SPECIFICATION
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Issue 1
JCB HYDRAULIC BREAKERS (cont’d)
VIBRO-DAMPED BREAKERS (cont’d)
Hydraulic supply pressure rangeModel Nos. 929/05300 & 05500 69 - 86 bar 1000 - 1247 lb/in2
Model Nos. 929/07400 & 08300 90 - 110 bar 1300 - 1600 lb/in2
Hydraulic supply relief valve settingModel Nos. 929/05300 & 05500 76 bar min. 1100 lb/in2
Model Nos. 929/07400 & 08300 117 bar min. 1700 lb/in2 min.All models 138 bar max. 2000 lb/in2 max.
Hydraulic return line pressure 12 bar max. 174 lb/in2 max.
Breaker blow frequency 1500 blows/min -
Breaker shank size 32 mm 1.25 in.
Hydraulic supply oil type JCB Special Hydraulic Oil (part no. 4002/0224)
EHTMA Category ‘C’ or ‘D’
‘D’ and ‘T’ BREAKERS
Breaker weight (Dry with hoses)‘D’ Handle 12 kg 26.4 lb‘T’ Handle 14 kg 28.6 lb
Breaker length‘D’ Handle 645 mm 25.4 in.‘T’ Handle TBA mm TBA in.
Accumulator gas pressure (Nitrogen) 33 bar 480 lb/in2
Hydraulic supply flow rate 15 - 20 litre/min 3.3 - 4.5 gal/min
Hydraulic supply pressure range 50 - 65 bar 725 - 945 lb/in2
Hydraulic supply relief valve setting TBA bar min. TBA lb/in2 min.TBA bar max. TBA lb/in2 max.
Hydraulic return line pressure TBA bar max. TBA lb/in2 max.
Breaker blow frequency 1500 blows/min -
Breaker shank size 2.22 mm 0.875 in.
Hydraulic shank size JCB Special Hydraulic Oil (part no. 4002/0224)
ETHMA Category ‘C’
D3 SPECIFICATION
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Issue 1
NOISE AND VIBRATION DATA
Model No. Handle Type Noise Level EC Vibration WeightedDirective 84/457/ RMS Acceleration ISO
EEC (LWA) 8662 Part 5 (m/s2)
929/05300 Vibro-Damped 111 5.5
929/05400 Standard 111 18.9
929/05500 Vibro-Damped 111 5.5
929/05600 Standard 111 18.9
929/07400 Vibro-Damped 107 5.4
929/07200 Standard 107 16.6
929/08300 Vibro-Damped 108 6.0
929/08200 Standard 108 17.1
929/12900 ‘D’ Type 103 5.7
929/20400 ‘T’ Type 103 5.7
E1 INTRODUCTION
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Issue 1
HYDRAULIC POWERPACKS
The range of hydraulic powerpacks are categorised byEHTMA as Category ‘C’ or ‘D’ hydraulic powerpacksand can be safely used with any hydraulic tooldisplaying the EHTMA ‘C’ or ‘D’ decals as shownbelow.
! WARNINGYou must understand and follow the instructions inthis manual and any accompanying manuals. If youare unsure about anything ask your dealer oremployer. Do not guess, or you or others could bekilled or seriously injured.
GENERAL DESCRIPTION
The JCB Hydraulic powerpacks have been speciallydeveloped to provide a lightweight source of portablehydraulic power for the JCB handheld hydraulicbreakers and tools.
Despite their simple construction, the powerpacksincorporate many special features such as automatic,energy saving, engine speed control, a variablehydraulic flow and a unique hydraulic circuit design(patent applied for) which eliminates totally anypossibility of pulsation damage to the oil cooler.
All the major components are enclosed in a fullywelded tubular frame which also provides easy handholds to maximise portability. A balanced lifting pointis also provided.
This manual covers the BEAVER III, to operate thepowerpack efficiently and safely you must know thepowerpack and have the skill to use it. It is assumedthat personnel carrying out maintenance have at leasta sound knowledge of workshop practice, safetyprocedures and general techniques associated withthe repair of hydraulic equipment.
Note: It is important to quote the serial number whenmaking repairs or ordering parts.
c20LPM AT 138 BARETHMA CATEGORY
D30LPM AT 138 BARETHMA CATEGORY
TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "D" POWERPACKS
TO AVOID RISK OF INJURY CONNECT ONLY TO CATEGORY "C" POWERPACKS
E2 MAINTENANCE
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Issue 1
HYDRAULIC POWERPACKS
MAINTENANCE
Safety DecalsKeep all decals clean and readable. Replace lost ordamaged decals.
Before Operating the Machine.1 Check for cleanliness.2 Check for Damage.3 Check for Leaks.4 Make sure the fuel filler cap is tightly closed.5 Check Hydraulic Oil Level.6 Ensure the machine is positioned safely.7 Ensure that all hydraulic couplings are fully
servicable. Refer to Hydraulic Couplings.8 Ensure that any hydraulic tools you are planning to
use are compatible with the machine you areusing.
9 Check Engine Oil Level.10 Check the Fuel.
! WARNINGNever refuel with the engine running.
Operating in Low Temperatures1 Use the Correct Viscosity Engine Oil.
Refer to Engine Manufacturer’s Handbook.2 Keep the Battery at Full Charge.3 Fill the Fuel Tank at the End of each Working Day.4 Protect the Machine When not in Use.
Note: If the machine is to be used continually attemperatures below 0°C (32°F) consult your Dealer.
Connecting Hosesa Stop the engine.b Move the Output Control to the Off position.c Attach Return Line.d Attach Feed Line.
Note: The connector is locked when the collar isturned away from the ball.
e Start the engine and run the machine to fill up thehydraulic circuit.
f Check the hydraulic oil level.
Checking the Hydraulic Oil Level1 Prepare the Machine - Position the machine on
level ground. Switch off the engine and allow it tocool down.
2 Check the Hydraulic Oil Level using the sight levelgauge.
3 If necessary top up the Hydraulic Oil using the fillerport.
Service Schedules
Apart from the daily jobs, the schedules are based onmachine running hours. Keep a regular check of hoursin use. Do not use a machine which is due for a regularservice. Rectify any defects found during regularmaintenance before clearing the machine for use.
! WARNINGMaintenance must only be done by suitablyqualified and competent persons. Before doing anymaintenance, make sure the machine is safe andcorrectly sited on level ground.
Daily1 Clean the machine generally. Clean the
machine using water and/or steam. Do notallow mud to build up on the engine. Makesure that the air inlets on the hydraulic coolerare not clogged.
Check2 Generally for damage.3 Hydraulic oil level.4 Engine oil level.5 Hydraulic couplings.6 Hydraulic hoses.
Note: Check the tightness of nuts, bolts, screws andhose fittings after the first days operation andthereafter in accordance with the Service Schedules.
Note: The engine oil should be replaced after the firstthree days and thereafter in accordance with theMaintenance Schedules.
Every 3 Months Do the Daily jobs plus:Clean1 Air cleaner elements.
Refer to Engine Manufacturer’s Handbook2 Engine oil filter.
Change3 Engine oil.4 Hydraulic oil filter.5 Hydraulic oil.
Every 6 MonthsDo the Daily and 3-monthly jobs plus:Check6 Tightness of nuts, bolts, screws and hose fittings.7 Flow and pressure output.
Change8 Main hydraulic filter.9 Hydraulic oil.10 Engine oil.
Refer to Engine Manufacturer’s Handbook
Clean11 Fuel strainer.12 Spark plug - Petrol model only - check plug gap -
Refer to Engine Manufacturer’s Handbook
E3 MAINTENANCE
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Issue 1
HYDRAULIC POWERPACKS
Changing the Hydraulic Oil
1 Prepare the Machine - Position the machine onlevel ground. Switch off the engine and allow it tocool down.
2 Place a container of suitable size below thehydraulic tank.
3 Remove the tank drain plug and filler cap to allowthe oil to drain out.
4 Clean and refit the drain plug.5 Pour hydraulic oil into the tank through the filler
until it reaches the required level in the sight glass.6 Refit the filler cap.
Note: Use only the recommended hydraulic oil.
Changing the Main Hydraulic Filter
! WARNINGHot oil and engine components can burn you. Makesure the engine is cool before doing this job.
1 Prepare the Machine - Position the machine onlevel ground. Switch off the engine and allow it tocool down.
2 Place a container of suitable size below the filter tocatch any spilt oil.
3 Remove the bolts securing the lid to the hydraulicfilter housing and remove the lid.
4 Lift out and dispose of the filter.5 Push the new element firmly into place in the filter
housing.6 Refit the lid on the filter housing, ensuring that the
spring clip locates between the spigots. Securewith the bolts.
7 Check the hydraulic oil level. Refer to Checkingthe Hydraulic Oil Level.
! WARNINGThere may be limited oil spillage when the filter isremoved. Clean any spillage immediately anddispose of materials in accordance with currentregulations.
Cleaning the Cooler
The oil cooler fins may be cleaned using low pressurecompressed air. Do not attempt to clean using a wirebrush as this could damage the fins.
Checking the Electrolyte Level
! WARNINGBattery electrolyte contains sulphuric acid. It canburn you if it touches your skin or eyes. Wearsafety glasses and handle the battery carefully toprevent spillage.
1 Prepare the Machine - Position the machine onlevel ground. Switch off the engine and allow it tocool down.
2 Unscrew and remove the battery covers.3 Look at the level in each cell. The electrolyte
should be 6mm(1/4in) above the plates.4 Top up if necessary with distilled or de-ionised
water.5 Refit the battery covers.
Gaining Access to Machine Components
To facilitate easier maintenance, the tubular frame isfitted with hinge bolts. The frame may be moved toafford ready access to the machine components in thefollowing manner:
1 Remove and retain the securing clips.2 Lift the tubular frame out of the way of the
machine components by hinging it on the bolts.
Note: It is important that after maintenance, thetubular frame is restored to its operating position andthat the clips are securely fitted.
Note: When the machine is to be lifted using thebalanced lifting point, it is important to ensure that theclips are in place and securely fitted.
Cleaning
It is expected that components will be thoroughlycleaned and lubricated, where appropiate, also thatany opened hose connections will be blanked toprevent entry of dirt and excessive loss of hydraulic oil.
Serial Numbers
Serial numbers are stamped on a spacer plate locatedbetween the engine and the hydraulic tank.
E4 SPECIFICATIONS
9803/1250
E4
Issue 1
HYDRAULIC POWERPACKS
Engines
The BEAVER III may be fitted with a Honda GX240petrol engine. These engines are fitted with an Oil Alertsystem which is designed to prevent engine damagecaused by an insufficient amount of oil in the crankcase. The oil alert system will shut down the enginebefore the oil in the crankcase can fall below a safelimit.If the Oil Alert system has shut down the engine thenOil Alert indicator will flash when you attempt to restartthe engine.
If the Lombardini 15LD315 is fitted it will either be aRecoil Start Model or an Electric Start Model.
Recoil Start Model: Pull the starter grip lightly untilresistance is felt, then pull briskly. Do not allow thestarter grip to snap back against the engine. Return itgently to prevent damage.
Electric Start Model: Do not use the electric starterfor more than 5 seconds at a time. If the engine fails tostart, release the key and wait 10 seconds beforeoperating the starter again.
After starting, allow the engine to idle for a fewminutes, then slacken the engine speed control.
Temperature Idling TimeThe following times are recommended for allowing theengine to idle when the temperatures are as indicated.
below -20 °C (-4 °F) 5 minutes-20 °C to -10 °C (-4 °F to 14 °F) 2 minutes-10 °C to 5 °C (14 °F to 41 °F) 1 minuteabove 5 °C (above41 °F) 20 seconds
